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Thermcraft XST-2-0-12-1V1-E28, Instruction Manual

The Thermcraft XST-2-0-12-1V1-E28 is a top-of-the-line heating system. To ensure seamless operation, we provide a comprehensive Instruction Manual that you can conveniently download for free from our website. This essential manual will guide you through the setup and maintenance of your device, guaranteeing optimal performance.

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11. TOXICOLOGICAL INFORMATION 
 
HEALTH DATA SUMMARY 
Epidemiological studies of RCF production workers have indicated no increased incidence 
of respiratory disease nor other significant health effects. In animal studies, long-term, 
high-dose inhalation exposure resulted in the development of respiratory disease in rats 
and hamsters. 
 
EPIDEMIOLOGY 

In order to determine possible human health effects following RCF exposure, the University of 
Cincinnati in the United States and the Institute of Occupational Medicine (IOM) in Europe have 
conducted medical surveillance studies on RCF workers in U.S. and European manufacturing 
facilities. The University of Cincinnati study has been in progress for over 20-years, collecting 
data from respiratory questionnaires, lung function tests, and chest X-rays, exposure monitoring, 
and worker mortality.  
 
The results of this study of RCF plant workers exposed from 1953 to the present have shown 
(LeMasters 

et al

, 2003): No excess mortality related to all deaths, all cancers, or lung cancer No 

statistically significant increase in interstitial findings (fibrosis), and 
No mesotheliomas or increase in lung cancer The initial cross-sectional spirometry studies in the 
U.S. (LeMasters 

et al.

1998) and Europe (Cowie 

et al.

2001) revealed lung function decrements in 

the RCF-exposed cohort that were associated with heavier historical exposures. Subsequently, 
longitudinal studies have revealed no RCF exposure related decrements in lung function 
associated with current exposure levels. 
 
Through 1996, pleural plaques seen on chest X-rays in 2.7% of the workers. Pleural plaques are 
considered a marker of exposure and not disease. The prevalence of pleural plaques has 
remained relatively constant over time, perhaps as a result of lower current exposure levels. 
Thus, this long term epidemiology study has demonstrated an absence of interstitial fibrosis, no 
increased mortality risk and no decrement in lung function associated with current exposures. 

 
TOXICOLOGY 

Early animal studies of RCF effects by intraperitoneal and intrapleural injections, as well as by 
inhalation, resulted in mostly negative results. In an effort to eliminate any questions posed by the 
results of these early studies, a definitive 

Maximum Tolerated Dose Study 

(MTD) by nose only, 

lifetime inhalation in rats and hamsters, was designed in the 1980s. The MTD study appeared to 
confirm that RCF was an animal carcinogen under certain test conditions, e.g., extremely high 
concentrations of approximately 200 f/cc inhaled directly into the lungs. 
A later review of the MTD pathology indicated that the animals’ lungs were likely “overloaded” 
because of large quantities of non-fibrous particles, and that this overload condition was likely 
responsible for the disease observed. In fact, evaluation of the aerosol samples used confirmed 
the presence of significant quantities of particulate matter. 
In a subsequent multi-dose animal inhalation study at 25 f/cc, 75 f/cc, and 115 f/cc; a 

no observed 

effect level 

(NOEL) was found at 25 f/cc. This level is 50 times the RCFC recommended REG of 

0.5 f/cc for 
humans. 

 
12. ECOLOGICAL INFORMATION 

No ecological concerns have been identified. 

 
13. DISPOSAL CONSIDERATIONS 
 
WASTE MANAGEMENT 

Summary of Contents for XST-2-0-12-1V1-E28

Page 1: ...s furnace has been completely checked for mechanical and electrical compliance prior to shipment We trust you have received your furnace in acceptable condition and that you will find it meets or exceeds your expectations and requirements Prior to installation and operation of your new Thermcraft Inc furnace we strongly urge you to read this manual it its entirety and comply with all instructions ...

Page 2: ...al Safety 7 Furnace Start Up Procedure 8 Preventive Maintenance 9 Thermocouple 10 Ceramic Fiber Insulation Safety 11 Replacement Parts List 12 Furnace Trouble Shooting 13 Fibercraft MSDS sheet 14 Control System Operation 15 Furnace Heater Wiring Diagram 16 Furnace Assembly Drawing 17 Electrical Wiring Diagram 18 Controller Manuals Eurotherm 3216 p 30 followed by Eurotherm 2416 p 172 Terms and Cond...

Page 3: ...1V1 E29 XST 2 0 12 1V2 E28 XST 2 0 12 1V2 E29 Maximum Temperature 1100 C Heater Type Vacuum formed with embedded electrical resistance wire Incoming Power Models XST 2 0 12 1V1 E28 and XST 2 0 12 1V1 E29 Volts 120 Amps 15 Watts 1200 Phase 1 Hertz 60 Models XST 2 0 12 1V2 E28 and XST 2 0 12 1V2 E29 Volts 208 240 Amps 8 220V Watts 1200 Phase 1 Hertz 50 60 ...

Page 4: ... the carrier will arrange for official inspection to substantiate your claim Verify that all of the equipment shown on the packing slip is included with the unit Carefully check all packing materials RETURN SHIPMENT Save the shipping box crate until you are sure all is well If for any reason you must return the unit first contact our Sales Department at 336 784 4800 Please have the unit s serial n...

Page 5: ...blower motors and conveyors may have been disassembled from the furnace to accommodate shipping Before proceeding with installation review all of drawings and diagrams included in this manual 1 Refer to designs making sure all furnace stands control boxes terminal boxes doors etc are in place and secure If not locate the appropriate parts that are included in the shipment and follow the furnace de...

Page 6: ...ns 1 Temperature effects 1 1 Thermocouple DC mV and DC V input 2u V C or 0 02 of F S C whichever is the larger 1 2 Resistance temperature detector 0 05 C C 1 3 Analog output 0 05 of F S C 2 Effect from fluctuation of power supply voltage within rated voltage range 2 1 Analog input 0 2u V V or 0 002 of F S V whichever is the larger 2 2 Analog output 0 05 of F S V Transportation and Storage Conditio...

Page 7: ...ef fittings for tightness See Torque Recommendation for Strain Relief Fittings chart below TORQUE RECOMMENDATIONS FOR STRAIN RELIEF FITTINGS Torque in Inch Pounds in lb Newton Meters Nm METAL STRAIN RELIEF FITTINGS PLASTIC STRAIN RELIEF FITTINGS DOME NUTS THREAD AND LOCK NUTS DOME NUTS THREAD AND LOCK NUTS PG 7 M12x1 5 36 9 4 17 55 3 6 25 14 4 1 62 22 1 2 50 PG 9 PG 11 M16 PG 13 5 3 8 NPT 1 2 NPT ...

Page 8: ...erminal box and is visible to the installer operator If unsure of the grounding status of the equipment consult the NEC National Electric Code or a licensed professional 3 If electrically conductive material is to be heat treated the operator must be protected from becoming a conductor to the ground To avoid electric shock observe the following operating practices a Wear insulated gloves specific ...

Page 9: ...perty damage Periodically disconnect power from the equipment and allow it to cool completely Once cool inspect for loose or broken heaters and for worn wire coils on the inside of the heated chamber Heaters may have to be replaced if damage is severe Avoid contact with any exposed heater coils elements Do not touch elements with bare hands or oily gloves Contact Thermcraft Inc if unsure of the sa...

Page 10: ...the moisture out of the refractory lining 3 Maintain the furnace at 300 F for four to six hours or till all smoke steam has subsided 4 Ramp the furnace up to 600 F and hold this temperature until all steam smoke has dissipated 5 If the furnace is still steaming smoking after 600F repeat this step 4 at 900 F 6 After all steam smoke is gone run furnace up to operating temperature 7 If steam smoke ap...

Page 11: ...of the furnace prior to heating Use caution not to displace the heating elements as the wire may be brittle and break easily 3 If furnace has a door verify that the door safety switch is operating and cutting the power to the heaters once the door is opened 4 If your furnace is equipped with a blower motor or has moving parts lubricate grease fittings as required 5 Check all hardware fasteners to ...

Page 12: ... functioning it is important to replace the malfunctioning thermocouple with the same type model thermocouple that was originally provided with the furnace Replacement extension wires and connectors must also be compatible with the thermocouple and the controller If your system has a Eurotherm controller a failed thermocouple will be indicated by SBR on the display and for a Yokogawa controller it...

Page 13: ...e of respiratory disease in the Refractory Ceramic Fiber Coalition s studies examining occupationally exposed workers In their animal testing long term laboratory exposure to doses hundreds of times higher than normal occupational exposures has produced fibrosis lung cancer and mesothelioma in rats or hamsters The fibers used in those studies were specially sized to maximize rodent reparability Pl...

Page 14: ...o take soiled clothing or any clothing in which fibers have become embedded from the facility where the furnace is employed to his her dwelling Have employees store maintain and wash work clothing on site separately from other clothing Rinse washing machine thoroughly after washing clothing worn when handling ceramic fibers 4 Wear eye protection safety glasses or goggles and protective gloves at a...

Page 15: ...11 REPLACEMENT PARTS LIST Description Quantity Required FH 1212393 L 1 Lower heating element includes thermocouple FH 1212393 U 1 Upper heating element ...

Page 16: ...12 FURNACE TROUBLE SHOOTING ...

Page 17: ...142844 00 6 100 See Section 8 Exposure Controls Personal Protection for exposure guidelines 3 HAZARDS IDENTIFICATION EMERGENCY OVERVIEW WARNING POSSIBLE CANCER HAZARD BY INHALATION See Section 11 for more information CHRONIC EFFECT There has been no increased incidence of respiratory disease in studies examining occupationally exposed workers In animal studies long term laboratory exposure to dose...

Page 18: ...ation for RCF The Seventh Annual Report on Carcinogens 1994 prepared by the National Toxicology Program NTP classified respirable RCF as reasonably anticipated to be a carcinogen The American Conference of Governmental Industrial Hygienists ACGIH has classified RCF as A2 Suspected Human Carcinogen The Commission of The European Communities DG XI has classified RCF as a substance that should be reg...

Page 19: ...dia suitable for type of surrounding fire 6 ACCIDENTAL RELEASE MEASURES SPILL PROCEDURES Minimize creating airborne dust Dust suppressing cleaning methods such as wet sweeping or vacuuming should be used to clean the work area If vacuuming the vacuum must be equipped with a HEPA filter Compressed air or dry sweeping should not be used for cleaning 7 HANDLING AND STORAGE STORAGE Store in original c...

Page 20: ...ssion controlling tool designs and materials handling equipment designed to minimize airborne fiber emissions PERSONAL PROTECTION EQUIPMENT Respiratory Protection RCF When engineering and or administrative controls are insufficient to maintain workplace concentrations within the 0 5 f cc REG the use of appropriate respiratory protection pursuant to the requirements of OSHA Standards 29 CFR 1910 13...

Page 21: ...erings and full body clothing as necessary to prevent skin irritation Washable or disposable clothing may be used If possible do not take unwashed clothing home If soiled work clothing must be taken home employers should ensure employees are thoroughly trained on the best practices to minimize non work dust exposure e g vacuum clothes before leaving the work area wash work clothing separately rins...

Page 22: ...levels Through 1996 pleural plaques seen on chest X rays in 2 7 of the workers Pleural plaques are considered a marker of exposure and not disease The prevalence of pleural plaques has remained relatively constant over time perhaps as a result of lower current exposure levels Thus this long term epidemiology study has demonstrated an absence of interstitial fibrosis no increased mortality risk and...

Page 23: ...ed hazard Toxic Substances Control Act TSCA RCF has been assigned a CAS number however it is an article under TSCA and therefore exempt from listing on the TSCA inventory Comprehensive Environmental Response Compensation and Liability Act CERCLA and the Clean Air Act CAA RCF contains fibers with an average diameter greater than one micron and thus is not considered a hazardous air pollutant OSHA C...

Page 24: ...ter service RCF showed little or no activity where exposure was by inhalation or by intraperitoneal injection and 2 after service RCF was not cytotoxic to macrophage like cells at concentrations up to 320 g cm by comparison pure quartz or cristobalite were significantly active at much lower levels circa 20 g cm RCF AFTER SERVICE REMOVAL Respiratory protection should be provided in compliance with ...

Page 25: ...tection Standards 29 CFR 1910 1200 1926 59 OSHA Hazard Communication Standards PEL Permissible Exposure Limit OSHA PIN Product Identification Number PNOC Particulates Not Otherwise Classified PNOR Particulates Not Otherwise Regulated PSP Product Stewardship Program RCFC Refractory Ceramic Fibers Coalition RCRA Resource Conservation and Recovery Act REG Recommended Exposure Guideline RCFC REL Recom...

Page 26: ...rate disconnect 2 Study all instrument manuals before energizing the control system and furnace 3 Review all electrical wiring diagrams 4 Make all external wire connections specified in the electrical wiring diagrams including connection of the cables between the furnace and the control console All conduit supplied shall be permanently secured mounted during the installation process CAUTION Contro...

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Page 31: ...3216 3208 3204 User Manual 3200 Range Process Controller HA028651 11 Aug 2012 ...

Page 32: ...the equipment to which the document relates without the prior written permission of Eurotherm Limited Eurotherm Limited pursues a policy of continuous development and product improvement The specification in this document may therefore be changed without notice The information in this document is given in good faith but is intended for guidance only Eurotherm Limited will accept no responsibility ...

Page 33: ...mitter Inputs 12 2 7 Input Output 1 Output 2 13 2 7 1 Relay Output Form A normally open 13 2 7 2 Logic SSR drive Output 13 2 7 3 DC Output 13 2 7 4 Triac Output 13 2 7 5 Logic Contact Closure Input I O 1 only 13 2 8 Remote Setpoint Input 13 2 9 Output 3 13 2 10 Summary of DC Outputs 13 2 11 Output 4 AA Relay 14 2 12 General Note About Relays and Inductive Loads 14 2 13 Digital Inputs A B 14 2 14 C...

Page 34: ... 39 8 1 1 Input Types and Ranges 40 8 1 2 Operation of Sensor Break 41 8 2 PV Offset 42 8 2 1 Example To Apply an Offset 42 8 3 PV Input Scaling 42 8 3 1 Example To Scale a Linear Input 42 9 Input Output 43 9 1 Input Output Parameters 44 9 1 1 Input Output 1 List IO 1 44 9 1 2 Remote Digital Setpoint Select and Remote Fail 46 9 1 3 Sense 46 9 1 4 Source 46 9 1 5 Power Fail 46 9 1 6 Example To Conf...

Page 35: ... Alarm 1 77 12 4 Diagnostic Alarms 78 12 4 1 Out of Range Indication 78 13 Timer Programmer 79 13 1 Timer Parameters 79 13 2 Programmer 81 13 2 1 Threshold 81 13 2 2 Run End Digital Outputs 82 13 2 3 Event Output During a Segment 82 13 2 4 To Configure the Programmer 83 13 3 Example To Configure a Dwell Timer as a Simple Two Step Programmer 84 14 Recipe 87 14 1 To Save Values in a Recipe 87 14 2 T...

Page 36: ...o Configure Alarms 118 17 6 1 Example 1 Using the Wizard 118 17 6 2 Example 2 Using the Browser View 118 17 7 To Customise Messages 119 17 7 1 Example 1 Using the Wizard 119 17 7 2 Example 2 Using the Browser View 120 17 7 3 Example 3 Inverted Status Word 121 17 7 4 Example 4 Display the message OUT OF CONTROL if both Alarm 1 and Alarm 2 are active 122 17 8 To Promote Parameters 123 17 8 1 Example...

Page 37: ...on 10 1 Correct description of enumerations for parameter IM section 15 6 Issue 8 includes the following changes The description of the Programmer in sections 5 8 and 13 2 A more detailed description of loop tuning Updates to Appendix A Technical Specification Issue 9 includes the following changes Clarification of order codes for isolated and non isolated outputs in appropriate sections Add Tune ...

Page 38: ...ets of five digits show the Quick Start Code If the Quick Start Code shows the controller was supplied with default parameters and will need to be configured when it is first switched on This Manual takes you through all aspects of installation wiring configuration and use of the controller 1 2 Unpacking Your Controller The controller is supplied with Sleeve with the controller fitted in the sleev...

Page 39: ...nted in the same panel observe the minimum spacing shown 2 Fit the IP65 sealing gasket behind the front bezel of the controller 3 Insert the controller through the cut out 4 Spring the panel retaining clips into place Secure the controller in position by holding it level and pushing both retaining clips forward 5 Peel off the protective cover from the display 1 4 2 Panel Cut Out Sizes 1 4 3 Recomm...

Page 40: ...Ω 0 5Vdc OP RES250 500Ω 0 10Vdc OP RES500 2 Function Controller CC Programmer CP valve controller VC Valve programmer VP 5 AA Relay OP4 Disabled X Relay Form C R 1 Model No 1 16 DIN size 3216 1 8 DIN size vertical 3208 1 8 DIN horizontal 32h8 1 4 DIN size 3204 8 9 Product Manual Language English ENG French FRA German GER Italian ITA Spanish SPA 4 Outputs 1 2 and 3 3208 H8 04 OP1 OP2 OP3 L R R X R ...

Page 41: ...re not available see section 0 Key to symbols used in the wiring diagrams Logic SSR drive output Relay output Contact input mA analogue output Triac output Current transformer input Ensure that you have the correct supply for your controller Check order code of the instrument supplied Digital Communications EIA232 EIA485 or EIA422 2 Or Remote Setpoint IP See section 2 8 Output 4 AA Relay AA AB AC ...

Page 42: ...supply for your controller Check order code of the instrument supplied C NO C NO Line Supply 100 to 240Vac 48 to 62 Hz OR Low Voltage Supply 24Vac dc 10V Potential divider module Part No SUB21 IV10 10V Input Output 3 24V Transmitter Supply AA Relay OP4 B A COM Digital Comms Or Remote Setpoint IP See section 2 8 T C Sensor Input Pt100 V V VI LA C CT HF HE HD AC AB AA N L 3D 3C 3B 3A LC LB 2B 2A 1B ...

Page 43: ...drive output Relay output Contact input mA analogue output Triac output Current transformer input Ensure that you have the correct supply for your controller Check order code of the instrument supplied Digital Communications EIA232 or EIA485 Or Remote Setpoint IP See section 2 8 Output 4 AA Relay Line Supply 100 to 240Vac 48 to 62 Hz OR Low Voltage Supply 20 29Vac dc Input Output 1 1 CT input Digi...

Page 44: ...e may cause measurement errors 2 6 Sensor Input Measuring Input 2 6 1 Thermocouple Input Positive Negative Use the correct compensating cable preferably shielded 2 6 2 RTD Input PRT PRT Lead compensation The resistance of the three wires must be the same The line resistance may cause errors if it is greater than 22Ω 2 6 3 Linear Input mA or mV If shielded cable is used it should be grounded in one...

Page 45: ...d 3 5mA 22mA it will be used as the main setpoint If it is not valid or not connected the controller will try to use the Volts input Volts sensor break occurs at 1 11V The two inputs are not isolated from each other If neither remote input is valid the controller will fall back to the internal setpoint SP1 or SP2 and flash the alarm beacon The alarm can also be configured to activate a relay see s...

Page 46: ...lated from the current transformer input or the sensor input Switching 12Vdc at 40mA max Contact open 500Ω Contact closed 200Ω Input functions Please refer to the list in the quick codes If EIA232 digital communications is fitted 3216 only Digital Input A is not available 2 14 Current Transformer The current transformer input is an optional input in all 3200 series controllers If EIA232 digital co...

Page 47: ... KD485 communications converter is recommended for Interfacing 4 wire to 2 wire connections To buffer an EIA422 485 network when more than 32 instruments on the same bus are required To bridge 2 wire EIA485 to 4 wire EIA422 Common Rx A Tx B Screen Local ground Com Rx Tx HD HE HF 220Ω termination resistor EIA232 EIA485 2 wire communications converter eg Type KD485 Daisy Chain to further controllers...

Page 48: ...quipment state A switch or circuit breaker shall be included in the building installation It shall be in close proximity to the equipment and within easy reach of the operator It shall be marked as the disconnecting device for the equipment A single switch or circuit breaker can drive more than one instrument 2 18 1 Example CT Wiring Diagram This diagram shows an example of wiring for a CT input N...

Page 49: ...recautions may cause damage to components of the instrument or some discomfort to the user Electrostatic discharge precautions When the controller is removed from its sleeve some of the exposed electronic components are vulnerable to damage by electrostatic discharge from someone handling the controller To avoid this before handling the unplugged controller discharge yourself to ground Cleaning Do...

Page 50: ...if any part of the system should fail In temperature control applications the primary danger is that the heating will remain constantly on Apart from spoiling the product this could damage any process machinery being controlled or even cause a fire Reasons why the heating might remain constantly on include the temperature sensor becoming detached from the process thermocouple wiring becoming short...

Page 51: ...Set 2 5 When the last digit has been entered press again the display will show Press or to The controller will then automatically go to the operator level section 4 3 SET 1 Input type Range Input Output 1 Output 2 Output 4 Thermocouple Full range X Unconfigured B Type B C oC H PID Heating logic relay 1 or 4 20mA or motor valve open VC and VP only Note 1 O P4 is relay only J Type J F oF C PID Cooli...

Page 52: ...e enter the Quick Configuration mode this can always be done as follows 1 Power down the controller 2 Hold down the button and power up the controller again 3 Keep the button pressed until code is displayed 4 Enter the configuration code this is defaulted to 4 in a new controller 5 The quick start codes may then be set as described previously Parameters may also be configured using a deeper level ...

Page 53: ...tor Level 3 see section 11 2 From firmware version 2 11 two further alarm types have been made available These are Rising rate of change An alarm will be detected if the rate of change units minute in a positive direction exceeds the alarm threshold Falling rate of change An alarm will be detected if the rate of change units minute in a negative direction exceeds the alarm threshold These alarms c...

Page 54: ...e active while Band and deviation alarm will be OFF 4 4 5 To Select Auto Manual or Off Mode Press and hold and Mode together for more than 1 second This can only be accessed from the HOME display 1 Auto is shown in the upper display After 5 seconds the lower display will scroll the longer description of this parameter ie lo op m ode au to m anua l o ff 2 Press to select mAn Press again to select O...

Page 55: ...configured xxx alarm type as follows HI High alarm LO Low alarm d HI Deviation high d LO Deviation low d HI Deviation high rrc Rising rate of change units minute Frc Falling rate of change units minute A2 xxx ALARM 2 SETPOINT A3 xxx ALARM 3 SETPOINT A4 xxx ALARM 3 SETPOINT LD AMP LOAD CURRENT Read only Only shown if CT is configured 5 Operator Level 2 Level 2 provides access to additional paramete...

Page 56: ...e section 10 1 SP1 SETPOINT 1 allows control setpoint 1 value to be adjusted Alterable SP HI to SP LO SP2 SETPOINT 2 allows control setpoint 2 value to be adjusted Alterable SP HI to SP LO SP RAT SETPOINT RATE LIMIT Rate of change of setpoint value OFF to 3000 display units per minute The next section applies to the Timer only see also section 5 4 TM CFG TIMER CONFIGURATION Configures the timer ty...

Page 57: ...red MTR T MOTOR TRAVEL TIME Set this value to the time that it takes for the motor to travel from its fully closed to its fully open position Note In motorised valve control only the PB and TI parameters are active see below The TD parameter has no effect on the control 0 0 to 999 9 seconds This section applies to control the parameters A further description of theses parameters is given in sectio...

Page 58: ...the measured leakage current when the power demand is off CT Range LD ALM LOAD CURRENT THRESHOLD Sets a low alarm on the load current measured by the CT Used to detect partial load failure CT Range LK ALM LEAK CURRENT THRESHOLD sets a high alarm on the leakage current measured by the CT CT Range HC ALM OVERCURRENT THRESHOLD Sets a high alarm on the load current measured by the CT CT Range ADDR ADD...

Page 59: ...MER RUNNING To Hold the timer Press and quickly release Beacon RUN Flashing Scrolling text display TIMER HOLD To Reset the timer Press and hold for more than 1 second Beacon RUN Off If the timer is a Dwell Type and configured to turn power off at the end of the timing period OFF will be displayed Timer has timed out END state Beacon RUN Off SPX On if End Type SP2 Scrolling display TIMER END Note T...

Page 60: ...ntrols at setpoint1 resets to Setpoint 1 SP2 Controls at setpoint 2 resets to Setpoint 1 rES Reset reverts to SP1 added from version V2 13 Note The dwell period can be reduced or increased while the timer is running 5 6 Delayed Timer TM CFG DELY The timer is used to switch on the output power after a set time The timer starts immediately on power up or when run The controller remains in standby wi...

Page 61: ...uired the ramp rate should be set to OFF 2 Where ramp dwell pairs are not required the ramp rate should be set to OFF and the target setpoint TSP the same as the preceding segment 3 TIMER END when the end type is SP2 Timer END does not occur until the ramp is complete or SP2 is achieved It is more usual to use a DWELL default or RESET end type A single program event output is also available To use...

Page 62: ...recovery from power failure the program will automatically run at the last ramp rate from the current measured temperature see the sketches below The behaviour of the programmer following a power failure is shown graphically below for SERVO SP rb and PV rb 5 8 2 To Operate the Programmer Operation of the programmer is the same as the timer Operation Action Indication To Run a program Press and qui...

Page 63: ...PV rb In this example the program will start from the current value of the process temperature See also section 5 8 1 Set the first Target Setpoint 11 Press to select TSP 1 12 Press or to adjust In this example the setpoint will ramp from the current value of the PV to the first target 100 Set the first Ramp Rate 13 Press to select RMP 1 14 Press or to adjust In this example the setpoint will ramp...

Page 64: ...nications address The instrument will continue to control when in Levels 1 2 or 3 6 1 2 Configuration Level This level makes available all parameters including the operation parameters so that there is no need to switch between configuration and operation levels during commissioning It is designed for those who may wish to change the fundamental characteristics of the instrument to match the proce...

Page 65: ...is 4 If an incorrect code is entered the display reverts to g o t o The controller is now in Configuration level will now show Conf 5 Press and hold for more than 3 seconds 6 Press to select the required level eg LEV 1 To Return to a Lower Level Conf got o Lev1 got o The choices are LEV 1 Level 1 LEV 2 Level 2 LEV 3 Level 3 C on F Configuration It is not necessary to enter a code when going from a...

Page 66: ...t is displayed as a mnemonic of four or five characters for example A1 TYP After a few seconds this display is replaced by a scrolling banner which gives a more detailed description of the parameter In this example A1 TYP a l a r m 1 type The scrolling banner is only shown once after the parameter is first accessed Views are shown for 3216 controllers The name of the list header is also displayed ...

Page 67: ...ut a List PROCESS INPUT LIST current transformer List Control List Recipe List Comms List Timer List Alarms List Setpoint List Calibration List Access List Sensor Input Parameters see Section 8 Output 1 or Input 1 Parameters see Section 9 Output 2 Parameters see Section 9 AA Relay Output 4 Parameters see Section 9 Digital Input Parameters see Section 9 CT Input Parameters see Section 9 Calibration...

Page 68: ... buttons when in operator levels If ALL has been selected then to restore access to the keyboard power up the controller with the button held down and enter the configuration level passcode as described in section 6 1 3 This will take you to the Quick Code mode Press to EX I T and select YES The front panel buttons can then be operated as normal none Unlocked none Conf ALL All buttons locked Edit ...

Page 69: ...0 and 100 so that a value of zero is centred in the display This indicates whether the controller is currently applying heating or cooling w sp The meter shows a representation of the current working setpoint scaled between the setpoint high and low limits It may be used to indicate at what point in the setpoint range the instrument is currently operating PV The meter displays the current Process ...

Page 70: ... performs is defined by its internal parameters Some of these parameters are available to the user so that they can be adjusted to suit the characteristics of the process which is to be controlled These parameters are found in lists and the name of each list corresponds with the name of the function block shown in the above diagram The above block diagram applies to 3208 32h8 and 3204 controllers ...

Page 71: ...ling Display Parameter Description Value Default Access Level IN TY P INPUT TYPE Selects input linearisation and range See section 8 1 1 for input types available Conf L3 R O U N IT S DISPLAY UNITS Display units shown on the instrument none No units only for custom linearisation o C L3 o C Celsius o F Fahrenheit o k Kelvin PErc D EC P DISPLAY POINTS Decimal point position nnnn No DP nnnn Conf L3 R...

Page 72: ...used by the Rate of Change Alarm functions Useful when commissioning to determine the level of filtering required on the Rate of Change alarm L3 8 1 1 Input Types and Ranges Input Type Min Range Max Range Units Min Range Max Range Units J tc Thermocouple type J 210 1200 oC 346 2192 oF k tc Thermocouple type K 200 1372 oC 328 2502 oF L tc Thermocouple type L 200 900 oC 328 1652 oF r tc Thermocouple...

Page 73: ...dication and output cancel For heat only OP HI and OP LO can be set between 0 0 and 100 For cool only OP HI and OP LO can be set between 100 0 and 0 SB TYP Lat Alarm latching Type of Output Output in Sensor Break Alarm State For heat cool OP HI and OP LO can be set between 100 SAFE value provided it is not set outside the output limits i e the same as Sbrk on ALM beacon flashes when an alarm occur...

Page 74: ... the Calibration section 16 8 3 PV Input Scaling Input scaling applies to the linear mV input range only This is set by configuring the INPUT TYPE parameter to mV and has an input range of 10 to 80mV Using an external burden resistor of 2 49Ω the controller can be made to accept 4 20mA from a current source Scaling of the input will match the displayed reading to the electrical input levels from t...

Page 75: ... O Sense Beacon lit when active Terminal 3216 3208 32h8 3204 I O 1 Heat Cool Alarm Retransmission setpoint temperature output Normal Inverted OP1 1A 1B OP 2 Heat Cool Alarm Retransmission setpoint temperature output Normal Inverted OP2 2A 2B OP 3 Heat Cool Alarm Retransmission setpoint temperature output Normal Inverted OP3 3A 3B OP4 AA Relay Heat Cool Alarm Normal Inverted OP4 AA AB AC LA Normal ...

Page 76: ...mission OP Output power demand re transmission 1 SRC A I O 1 SOURCE A These parameters only appear when the channel function is a Digital output i e 1 FUNC d out Selects an event status to be connected to the output channel The output status is the result of an OR of Src A Src B Src C and Src D Up to four events can therefore operate the output See section 9 1 4 none No event connected to the outp...

Page 77: ...relays from switching too rapidly 0 0 to 150 0 Auto or 1 0 to 150 0 seconds Auto 110mS 5 0 sec for relay Auto for logic Conf 1 SENS I O 1 SENSE To configure the sense of the input or output channel See also section 9 1 3 nor Inv Normal Inverted nor Conf 1 rn g DC OUTPUT RANGE To configure 0 20mA or 4 20mA output Only appears if the output module is DC output 0 20 0 20mA output L3 4 20 4 20mA outpu...

Page 78: ... a relay If any one of the events becomes true then the output relay will operate 9 1 5 Power Fail An output configured as a digital output can be made to operate following a power fail It can be acknowledged in the same manner as an alarm but no alarm message is given 9 1 6 Example To Configure IO 1 Relay to Operate on Alarms 1 and 2 Do This Display Additional Notes 1 From any display press as ma...

Page 79: ...le re transmission OP Output power demand re transmission 2 SRC A I O 2 SOURCE A These parameters only appear when the channel function is a Digital OP i e 2 FUNC d Out Selects an event status to be connected to the output channel The output status is the result of an OR of Src A Src B Src C and Src D Up to four events can therefore operate the output See section 9 1 4 none No event connected to t...

Page 80: ...on Op Output re transmission 3 SRC A I O 3 SOURCE A These parameters only appear when the channel function is a Digital OP i e 3 FUNC d Out Selects an event status to be connected to the output channel The output status is the result of an OR of Src A Src B Src C and Src D Up to four events can therefore operate the output See section 9 1 4 none No event connected to the output none Conf AL1 Alarm...

Page 81: ...4 SOURCE A These parameters only appear when the channel function is a Digital OP i e 4 FUNC d Out Selects an event status to be connected to the output channel The output status is the result of an OR of Src A Src B Src C and Src D Up to four events can therefore operate the output See section 9 1 4 none No event connected to the output none Conf AL1 Alarm 1 4 SRC B I O 4 SOURCE B AL2 Alarm 2 AL3...

Page 82: ...C INPUT LIST la LB Name Scrolling Display Parameter Description Value Default Access Level L TYPE LOGIC INPUT TYPE Input channel type L IP Logic input As order code Conf Read only L d in LOGIC INPUT FUNCTION To configure the function of the digital input none Input not used Ac AL Conf Ac AL Alarm acknowledge SP2 Setpoint 2 select Loc b Front keypad disable t res Timer programmer reset t run Timer ...

Page 83: ...nput The source can only be selected if the output has been configured for Heat or Cool none None IO 1 Input output 1 OP 2 Output 2 aa AA Relay CT RNG CT RANGE Sets the CT inputs range 0 to CT full scale value 1000 As order code Conf CT LAT CT ALARM LATCH TYPE To configure the latch mode of the CT input alarm A description of alarm latching is given in the alarm section nonE No latching no Conf if...

Page 84: ...w range limit to Setpoint high limit SP HI Also limited by the rng hi and rng lo parameters Range Low Limit L3 rE m s p REMOTE SETPOINT Reads the current remote setpoint value when remote setpoint is in use Read only l r REMOTE SETPOINT SELECT To select the remote digital communications setpoint No Not selected no Conf YES Selected S P R A T SETPOINT RATE LIMIT Limits the rate of change of the set...

Page 85: ... to scroll to SP2 5 Press or to adjust setpoint 2 6 Press as many times as necessary to scroll to SP RAT 7 Press or to set the rate at which you require the setpoint to change Whenever the setpoint is changed the controller will ramp from its current setpoint to the new value at the rate set in units per second minute or hours as set by the RAMPU parameter It will also change at the same rate when...

Page 86: ...be reduced and relay chatter is to be avoided If cooling is used cooling power is turned on when the PV is above setpoint and off when it is below It is suitable for controlling switching devices such as relays contactors triacs or digital logic devices 11 1 2 PID Control PID also referred to as Three Term Control is an algorithm which continuously adjusts the output according to a set of rules to...

Page 87: ...f the manual power Effectively when the raise or lower key is pressed 100 or 100 velocity is used for the duration of the key press and the raise or lower output is turned on In boundless mode it is essential that the Motor Travel Time MTR T is set correctly in order for the integral time to calculate correctly Motor travel time is defined as valve fully open valve fully closed it is not necessari...

Page 88: ...ABLE OFF Auto tune off OFF L3 On Set to on to start auto tuning FaiL Displayed if Autotune cannot be completed A T R 2G AUTOTUNE CONFIGURES R2G See section 11 4 for an explanation YES R2G will be set by Auto tune yes Conf No Allows a value for R2G to be entered manually P B PROPORTIONAL BAND See also section 11 2 1 0 1 to 9999 display units or 1 to 999 9 if proportional band expressed as 20 L3 T I...

Page 89: ...ut level in a sensor break open circuit condition 100 0 to 100 0 limited by OP HI and OP LO 0 0 L3 F M O D FORCED MANUAL OUTPUT MODE Selects how the loop behaves on transfer from Auto to Manual Transfer from Manual to Auto is always bumpless none Transfer between Auto Manual Auto is bumpless none L3 SteP Transfer from Auto to Manual the output goes to a pre set value F OP Last Transfer from Auto t...

Page 90: ...ing unstable The proportional band may be set in engineering units or as a percentage of the controller range 11 2 2 Integral Term TI In a proportional only controller an error between setpoint and PV must exist for the controller to deliver power Integral is used to achieve zero steady state control error The integral term slowly shifts the output level as a result of an error between setpoint an...

Page 91: ... however there are situations where derivative may be the cause of instability For example if the PV is noisy then derivative can amplify that noise and cause excessive output changes in these situations it is often better to disable the derivative and re tune the loop If set to Off 0 no derivative action will be applied In 3200 controllers derivative is calculated on change of PV For applications...

Page 92: ...ttle precisely at setpoint The Manual Reset parameter MR represents the value of the power output that will be delivered when the error is zero You must set this value manually in order to remove the steady state error 11 2 7 Control Action When set to reverse R EV the output increases when the PV is below setpoint This is the best setting for heating control For cooling control only set Control A...

Page 93: ...rther decaying oscillations before settling once again Critically Damped This represents an ideal situation where overshoot to small step changes does not occur and the process responds to changes in a controlled non oscillatory manner Over Damped In this situation the loop responds in a controlled but sluggish manner which will result in a loop performance which is non ideal and unnecessarily slo...

Page 94: ...s started Input Filter Time Constant The parameter FILTER TIME should be set before tuning the loop It is found in the INPUT List Valve Travel Time If the output is a motor valve positioner the parameter MTR T Control List should be set to the time that it takes for the motor to travel from its fully closed to its fully open position Other Considerations If a process includes adjacent interactive ...

Page 95: ...vels 2 or 3 set the AUTO TUNE ENABLE parameter to On Press the Page and Scroll buttons together to return to the Home display The display will flash Tune to indicate that tuning is in progress A One shot Tune can be performed at any time but normally it is performed only once during the initial commissioning of the process However if the process under control subsequently becomes unstable because ...

Page 96: ... heating and cooling power remains off for a period of 1 minute to allow the algorithm to establish steady state conditions B to D First heat cool cycle to establish first overshoot CBLO is calculated on the basis of the size of this overshoot assuming it is not set to Auto in the initial conditions B to F Two cycles of oscillation are produced from which the peak to peak response and the true per...

Page 97: ... calculated on the basis of the size of the overshoot assuming it was not set to Auto in the initial conditions CBHI is then set to the same value as CBLO Note As with the heat cool case Autotune can also occur when the initial PV is above SP The sequence is the same as tuning from below setpoint except that the sequence starts with natural cooling applied at B after the first one minute settling ...

Page 98: ...e at setpoint is abandoned Tuning is then resumed as a tune from above or below setpoint depending on which way the PV has drifted Since the loop is already at setpoint there is no need to calculate a Tune Control Setpoint the loop is forced to oscillate around the Target Setpoint C to G Initiate oscillation the process is forced to oscillate by switching the output between the output limits From ...

Page 99: ...of the proportional band value PB and the period of oscillation T If PV is already oscillating measure the period of oscillation T then increase the proportional band until it just stops oscillating Make a note of the value of the proportional band at this point Set the proportional band integral time and derivative time parameter values according to the calculations given in the table below Type ...

Page 100: ...lay units This can be calculated by taking the value in percentage that has been installed into the parameter PB and entering it into the following formula PB 100 Span of controller Cutback High and Cutback Low For example if PB 10 and the span of the controller is 0 1200OC then Cutback High and Low 10 100 1200 120 If overshoot is observed following the correct settings of the PID terms increase t...

Page 101: ...alue for R2G One way to approximate a suitable value for R2G is to measure the heating and cooling rates around the normal operating temperature of the system 1 Measure the heating and cooling rates of the process a Put the controller into Manual mode and turn heating power ON limited by OP HI b Allow the process to heat from below normal operating setpoint and for the actual temperature to pass t...

Page 102: ...ed PId PID 3 term control on ofOn Off control 6 Press to select CTRL A 7 Press or to rev Control Action choices are rev Reverse heating control Dir Direct cooling only control 8 Press to scroll to PB UNT 9 Press or to choose units Proportional Band Units choices are EnG Engineering units Perc Percentage 10 Continue to select parameters using for example OP HI 11 Press or to change their values Whe...

Page 103: ...rs take time to complete their cycle thus ensuring that heating and cooling are not being applied at the same time Deadband is likely to be used therefore in on off control only The second example below adds a deadband of 20 to the above example In an on off controller if CONTROL ACTION rev then OP2 will be on when PV is below SP OP1 will be on when the PV is above SP The outputs are therefore rev...

Page 104: ...ator Level 2 see section 11 2 For a PRT input sensor break is indicated if any one of the three wires is broken For mA input sensor break will not be detected due to the load resistor connected across the input terminals For Volts input sensor break may not be detected due to the potential divider network connected across the input terminals Loop Break alarm Displayed as CONTROL LOOP BROKEN This o...

Page 105: ...configured using iTools as described in section 17 7 If a message has been configured it will scroll across the display while the event is true Blocking Alarms The alarm may be masked during start up Blocking prevents the alarm from being activated until the process has first achieved a safe state It is used to ignore start up conditions which are not representative of running conditions A blockin...

Page 106: ...es are flashed in turn in the main display The alarm indication will continue while the alarm condition is present and is not acknowledged ALM beacon on continuously alarm has been acknowledged 12 1 3 To Acknowledge An Alarm Press and together The action which now takes place will depend on the type of latching which has been configured Non Latched Alarms Alarm condition present when the alarm is ...

Page 107: ...ior to the power cycle the alarm will return safe but not acknowledged For a manual latching alarm blocking will not be re instated and the active alarm will remain active If the alarm condition has gone safe during the downtime the alarm will return safe but not acknowledged If the alarm was safe but not acknowledged prior to the power cycle the alarm will return safe but not acknowledged The fol...

Page 108: ...t in 1 9999 eng units min A 1 ALARM 1 SETPOINT Alarm 1 threshold value The last three characters show the type of alarm configured from the above list Instrument range 0 L3 A 1 s ts ALARM 1 OUTPUT Indicates the status of the alarm OFF Alarm off Read only On Alarm on A1 HYS ALARM 1 HYSTERESIS See description at the beginning of this section 0 to 9999 Conf A1 LAT ALARM 1 LATCHING TYPE See descriptio...

Page 109: ... the type of alarm configured from the above list The alarm threshold is shown in the upper display In this example the high alarm will be detected when the measured value exceeds 215 6 Press to select A1 STS This is a read only parameter which shows the status of the alarm output 7 Press to select A1 HYS 8 Press or to set the hysteresis In this example the alarm will cancel when the measured valu...

Page 110: ...will not have been entered in the previous configuration E CaL Calibration error Re instate Factory calibration E2 Er EEPROM error Return to factory for repair EE Er Non vol memory error Note the error and contact your supplier E Lin Invalid input type This refers to custom linearisation which may not have been applied correctly or may have been corrupted Go to the INPUT list in configuration leve...

Page 111: ...imer starts Dwell timer and Programmer only Off or 1 to 3000 Units above and below setpoint Off L3 EN d T TIMER END TYPE To determine the action which takes place when the timer has timed out Dwell timer and Programmer only OFF Control outputs go to zero Conf DwEl Control continues at SP1 SP2 Go to setpoint 2 res Reset programmer SS SP SOFT START SETOINT Sets the threshold below which the power is...

Page 112: ...ree parameters are repeated for the next 3 program segments i e TSP 2 3 4 RMP 2 3 4 DWEL 2 3 4 d w e l l SET TIMER DURATION To set the time duration not programmer 0 00 to 99 59 hh mm or mm ss 0 L3 T E LAP ELAPSED TIME Time elapsed from when the timer starts to run 0 00 to 99 59 hh mm or mm ss L3 read only T R EM N TIME REMAINING Time remaining to reach the set time 0 00 to 99 59 hh mm or mm ss L3...

Page 113: ... end type is SP2 Timer END does not occur until the ramp is complete or SP2 is achieved It is more usual to use a DWELL End Type the default setting 13 2 1 Threshold A single threshold value is available to provide a holdback on the entry to the dwell part of the ramp dwell pair It holds back the dwell until the PV has reached the band defined by threshold around the PV as shown below Program RUNN...

Page 114: ...added after software version 2 A digital event may be configured to operate in any segment of the program This is set up in the TIMER List by the parameter EVENT To turn an output on in a segment use the table and diagram below to obtain the weighting value for that segment Note down the weightings for each segment in which the output is to be turned on and add them together Set the Event Settings...

Page 115: ... the process variable Set the first Target Setpoint Press to select TSP 1 Press or to adjust 100 Tsp 1 In this example the setpoint will ramp from the current value of the PV to the first target 100 Set the first Ramp Rate Press to select RMP 1 Press or to adjust 8 0 Rm p 1 In this example the setpoint will ramp to 100 at 8 0 units per hour The ramp units are set up in the Setpoint List see sectio...

Page 116: ...t signal Scrolling display i o 1 lis t Set the output function to digital out 2 Press twice to select 1 FUNC 3 Press or to choose d out d out 1 f unc Scrolling display i o 1 fu n c t io n Wire source A so that IO 1 operates when the timer end status is true 4 Press to scroll to 1 S R C A 5 Press or to choose t end t end 1 src a Also 1 s rc b 1 s rc c 1 s rc d none and 1 sens nor to energise the re...

Page 117: ...rnal contact Set the input to Run Reset the timer 15 Press to select L D I N 16 Press or to choose t rrs Make to Run break to Reset Configure the Timer Operation Do This Display View Additional Notes Select the Timer list header 17 Press as many times as necessary to select T I M E R tim er To configure the timer This can also be done in Level 3 Scrolling display t im e r lis t Configure the timer...

Page 118: ...value turned off Threshold value turned on This now behaves as a simple four segment programmer of two ramps two dwells Servo to PV start THRES OFF RUN RESET Digital input RUN Digital O P trun END Digital O P t End Temp SP1 70oC Time SP2 20 oC Ramp to SP1 at SP RAT DWELL Ramp to SP2 at SP RAT This point will also Servo to PV TIMER RUNNING Scrolling message TIMER END Ramp to SP1 at SP RAT Ramp to S...

Page 119: ...ng display R E C IP E L IS T 2 Press to scroll to S T O R E 3 Press or to choose the recipe number to store eg 1 Scrolling display R E C I P E TO S A V E The current parameter values are stored in Recipe 1 14 2 To Save Values in a Second Recipe In this example the proportional band will be changed and stored in recipe 2 All other values will remain the same as recipe 1 Do This The Display You Shou...

Page 120: ...eshold1 T i Integral time A 2 xx Alarm 2 threshold2 Td Derivative time A 3 xx Alarm 3 threshold3 d band Channel 2 deadband A 4 xx Alarm 4 hreshold4 C b lo Cutback low lb t Loop break time C b h i Cutback high H ys t h Channel 1 hysteresis R 2g Relative cool gain H ys t c Channel 2 hysteresis S p1 Setpoint 1 H om e Home Display S p2 Setpoint 2 S p h i Setpoint High limit M r Manual reset On off onl...

Page 121: ...se EIA485 buffer the EIA232 port of the PC with a suitable EIA232 EIA485 converter The Eurotherm Controls KD485 Communications Adapter unit is recommended for this purpose The use of a EIA485 board built into the computer is not recommended since this board may not be isolated which may cause noise problems and the RX terminals may not be biased correctly for this application To construct a cable ...

Page 122: ...face r422 EIA422 Modbus 3216 only dc ip Remote setpoint input If fitted this ID replaces the above and no further parameters are shown ADDR COMMUNIC ATIONS ADDRESS Communications address of the instrument 1 to 254 1 L3 BAUD COMMUNIC ATIONS BAUD RATE Communications baud rate 1200 1200 9600 Conf L3 R O 2400 2400 4800 4800 9600 9600 19 20 19 200 PR TY COMMUNIC ATIONS PARITY Communications parity none...

Page 123: ...ting the RETRN parameter to W SP PV OP or Err Once the function has been enabled the instrument will send this value out over the communications link every control cycle 250ms Notes 1 The parameter being broadcast must be set to the same decimal point resolution in both master and slave instruments 2 If iTools or any other Modbus master is connected to the port on which the broadcast master is ena...

Page 124: ...manently to address 26 Note however that any value written to the Target Setpoint will not be retained over a power fail since the controller then reverts to the setpoint selected for example SP1 or SP2 It is critically important to select the Alternate Setpoint if updating the setpoint on a regular basis otherwise the setpoint change will be saved to non volatile memory and EEPROM wear will resul...

Page 125: ...extual value for example off or on is sent as a simple integer value For floating point data the value is represented as a scaled integer in which the value is sent as an integer which gives the result of the value multiplied by 10 to the power of the decimal resolution for that value This is easiest to understand by reference to examples FP Value Integer Representation FP Value Integer Representa...

Page 126: ...are required consider using the internal ramp rate function or the remote comms setpoint Modbus address 26 in preference 24 SP2 Setpoint 2 NB do not write continuously changing values to this variable The memory technology used in this product has a limited 100 000 number of write cycles If ramped setpoints are required consider using the internal ramp rate function or the remote comms setpoint Mo...

Page 127: ...orced manual output value 84 F MOD Forced manual output mode 0 None 1 Step 2 Last 85 HYST H Ch1 On Off Hysteresis in Eng Units 86 Di IP Digital Inputs Status This is a bitmap B0 Logic input 1A B1 Logic input LA B2 Logic input LB B7 Power has failed since last alarm acknowledge A value of 1 signifies the input is closed otherwise it is zero Values are undefined if options are not fitted or not conf...

Page 128: ... sets low range for setpoint input corresponding to 4mA or 0V depending on the input type 279 ROP HI Sets the high range limit for the retransmitted setpoint Allows a subset of the setpoint range to be retransmitted and also allows the 3208 3204 setpoint range meter to display a range indication other than full scale By default this is set to the setpoint high limit 280 ROP LO Sets the low range l...

Page 129: ...rol 512 CTRL C Cool Ch2 Control Type 0 Off 1 On Off Control 2 PID Control 513 PB UNT Proportional Band Units 0 Engineering Units 1 Percent of Span 514 Lev2 P Level 2 Code 515 UNITS Display Units 0 Degrees C 1 Degrees F 2 Kelvin 3 None 4 Percent 516 Lev3 P Level 3 Code 517 Conf P Config Code 518 Cold If set to 1 instrument will reset to factory defaults on next reset or power cycle 519 PASS C Featu...

Page 130: ...1 BLOCK 547 Di OP Digital Outputs Status This is a bitmap B0 Output 1A B1 Output 2A B2 Output 3 on 32h8 and 3208 controllers B3 Output 4 AA It is possible to write to this status word to use the digital outputs in a telemetry output mode Only outputs whose function is set to none are affected and the setting of any bits in the Digital Output Status word will not affect outputs used for heat for ex...

Page 131: ...ammer Dwell 1 Duration 1280 TSP 1 Programmer Target Setpoint 1 1281 RMP 1 Programmer Ramp Rate 1 1282 Dwel 2 Programmer Dwell 2 Duration 1283 TSP 2 Programmer Target Setpoint 2 1284 RMP 2 Programmer Ramp Rate 2 1285 Dwel 3 Programmer Dwell 3 Duration 1286 TSP 3 Programmer Target Setpoint 3 1287 RMP 3 Programmer Ramp Rate 3 1288 Dwel 4 Programmer Dwell 4 Duration 1289 TSP 4 Programmer Target Setpoi...

Page 132: ...hrough IO1 52 Remote key UP 53 Remote key DOWN 12369 L SENS LB Configures the polarity of the logic input channel B 0 Normal 1 Inverted 3208 4 only 12377 ID Comms Module Type 0 None 1 EIA232 2 EIA232 3 EIA232 4 Remote setpoint input 12544 BAUD Baud Rate 0 9600 1 19200 2 4800 3 2400 4 1200 12548 PRTY Parity setting 0 None 1 Even 2 Odd 12549 DELAY RX TX Delay 0 no delay 1 delay Select if a delay is ...

Page 133: ...unc I O Channel Function 0 None or Telemetry Output 1 Digital Output 2 Heat or UP if valve position 3 Cool or DOWN if valve position 4 Digital Input 10 DC Output no function 11 DC Output Heat 12 DC Output Cool 13 DC Output WSP retransmission 14 DC Output PV retransmission 15 DC Output OP retransmission 12675 1 RNG IO Channel 1 DC Output Range 0 0 20mA 1 4 20mA 12676 1 SRC A IO Channel 1 Source A 0...

Page 134: ...ress 12678 12743 2 SRC C Output 2 source C As IO Channel 1 Source A Modbus address 12678 12744 2 SRC D Output 2 source D As IO Channel 1 Source A Modbus address 12678 12745 2 SENS Output 2 Polarity 0 Normal 1 Inverted 12746 2 PLS Output 2 Time proportioning Output minimum pulse time 12770 3 ID Output 3 Type 0 None 1 Relay 2 3 DC OP 12800 3 FUNC Output 3 Channel function 0 None or Telemetry Output ...

Page 135: ...n 3 Cool or DOWN if valve position 13059 4 SRC A Output AA source A As IO Channel 1 Source A Modbus address 12678 13062 4 SRC B Output AA source B As IO Channel 1 Source A Modbus address 12678 13063 4 SRC C Output AA source C As IO Channel 1 Source A Modbus address 12678 13064 4 SRC D Output AA source D As IO Channel 1 Source A Modbus address 12678 13065 4 SENS Output Polarity 0 Normal 1 Inverted ...

Page 136: ...ore removing the controller from its sleeve 5 Allow at least 10 minutes for the controller to warm up after switch on 16 1 2 To Check mV Input Calibration The input may have been configured for a process input of mV Volts or mA and scaled in Level 3 as described in section 8 3 The example described in section 8 3 1 assumes that the display is set up to read 2 0 for an input of 4 000mV and 500 0 fo...

Page 137: ...calibration is within 0 25 of reading 1LSD 16 2 Offsets The process value can be offset to take into account known errors within the process The offset can be applied to any Input Type mV V mA thermocouple or RTD A single offset can be applied the procedure is carried out in the INPUT list and has been described in section 8 2 It is also possible to adjust the low and high points as a two point of...

Page 138: ...t the low offset value eg 8 0 8 0 c adj This applies an offset over the whole range in the same way as a simple offset section 8 2 6 The controller then reverts to the CAL list header C A L This is the same as 1 above Set mV input to 20 00mV Select User Calibration 7 Press to scroll to U CAL IdLe ucal This is the same as 2 above Select the high calibration point 8 Press or to HI Hi ucal Select the...

Page 139: ...wires from the mV source and short circuiting the input to the controller To calibrate the mV Input select Conf Level as described in section 6 1 3 set the controller input to mV range then Operation Do This Display View Additional Notes Select the Calibration List header 1 From any display press as many times as necessary until the CAL page header is displayed Scrolling display C A L IB R A T IO ...

Page 140: ...ion Do This Display View Additional Notes Select the Calibration List header 1 From any display press as many times as necessary until the C A L page header is displayed Select the calibration phase 2 Press to select P H A S E none p ha se Scrolling display C A L IB R A T IO N p h a s e Select CJC calibration 3 Press or to select CJC Calibrate CJC 4 Press to select GO 5 Press or to choose YES The ...

Page 141: ...header 1 From any display press as many times as necessary until the C A L page header is displayed Scrolling display C A L IB R A T IO N L IS T Select the calibration phase 2 Press to select P H A S E none p ha se Scrolling display C A L IB R A T IO N p h a s e Set the decade box for 150 00Ω Select the low calibration point 150Ω 3 Press or to choose 150r Calibrate the low point 4 Press to select ...

Page 142: ...ss or to adjust this value so that it reads the same value as shown on the ammeter For example if the meter reads 2 06 then set the controller reading for 206 The decimal point is not displayed on the controller so that 200 represents 2 00 Scrolling message dc output reading Select high point calibration phase for the mA output to be calibrated eg OP1 5 Press to go back to PHASE 6 Press or to choo...

Page 143: ...e low calibration point 4mA 4 Press to select G O 5 Press or to choose YES Scrolling display C A L IB R A T IO N s ta r t The controller automatically calibrates to the injected input The display will show busy then pass if calibration is successful or FAIL if not Fail may be due to incorrect input mA Set mV source for 20mA Select the high calibration point 9 Press to select P H A S E 10 Press or ...

Page 144: ...l show busy then pass assuming a successful calibration If it is not successful then FAIL will be displayed This may be due to an incorrect input current Select the current transformer high point calibration phase 6 Press or to choose Ct 70 Ct70 p h as e Adjust the CT for a current of 70mA dc 7 Press to select GO 8 Press or to yes The controller again automatically calibrates to 70mA If it is not ...

Page 145: ...ion can only be done in Conf level CALIBRATION PARAMETER LIST cAL Name Scrolling Display Parameter Description Value Default Access Level p h a se CAL PHASE To calibrate low and high offset none Not selected none Conf only 0 Select mV low calibration point 50 Select mV high calibration point 150r Select PRT low cal point 400r Select PRT high cal point CJC Select CJC calibration Ct 0 Select CT low ...

Page 146: ... www eurotherm co uk If the build of your instrument is a non standard it may be necessary for you to download the IDM from the Eurotherm web site The file will be of the format id32i_v107 exe where id 32i is the instrument and V is the software version number of the instrument To load the IDM From windows START select Programs Eurotherm iTools Advanced Tools IDM Manager Then Install New IDM To re...

Page 147: ...milar to the one shown below will be displayed The browser on the left shows the List Headers To display parameters within a list double click the Header or select Parameter Explorer Click on a list header to display parameters associated with this list The instrument view may be turned on or off using the View menu and selecting Panel Views The instrument may be configured using a Wizard or from ...

Page 148: ...zard From the opening view shown in section 17 3 press The controller will be set to configuration level Since it will not operate the process in configuration level a warning message appears When this is accepted the Wizard start up screen is shown Select a tab to configure a function ...

Page 149: ...n Other parameters can also be set using the drop downs or by setting the analogue values Parameters shown in blue in the iTools view are not alterable A help text is shown to the right of the wizard This describes the feature which is selected A list of parameters which need to be configured follows this general description Click on the parameter for a description of its function To configure the...

Page 150: ...down menus Help text is shown together with a pictorial representation of the alarm operation 17 6 2 Example 2 Using the Browser View 1 Press to put the controller into Configuration level 2 Select the list header from the browser in this case ALARM 1 3 To configure Alarm Type open the drop down under the Value column 4 Select the alarm type in this example HI 1 is the enumeration of the parameter...

Page 151: ...s greater than the Value is less than the Value Set the value The bitmap list is given here and in the Digital Comms chapter 1 Click in the Value box and press enter 2 From the pop up box either tick the bit field values or type in the decimal equivalent in New Value In this example 3 alarm 1 alarm 2 Instrument Status Bitmap B0 Alarm 1 Status B1 Alarm 2 Status B2 Alarm 3 Status B3 Alarm 4 Status B...

Page 152: ...larm 3 Alarm 1 2 0010 Alarm 2 6 0110 Alarm 2 Alarm 3 3 0011 Alarm 1 Alarm 2 7 0111 Alarm 1 Alarm 2 Alarm 3 4 0100 Alarm 3 8 1000 Alarm 4 17 7 2 Example 2 Using the Browser View In this example the alarm 1 message will read TOO HOT 1 Press and select the Message Table tag 2 Select Parameter ALARM1 1 3 In the Message Condition area change Message to TOO HOT 4 Press Update Device Flash Memory button ...

Page 153: ...e previous example and adds the message PROCESS OK on the controller when the Alarm 1 condition is not true 1 Press and select the Message Table tag 2 Add the InverseStatus parameter as follows a Click where the parameter is required b Select Insert c Select STATUSInverseStatus from the pop up 3 In the Operator box select Mask 4 In the Value box select 1 Alarm 1 only 5 In the message box enter PRO...

Page 154: ...1 Status B1 Alarm 2 Status B2 Alarm 3 Status B3 Alarm 4 Status B4 Auto Manual Status B5 Sensor Break Status B6 Loop Break Status B7 CT Low load current alarm status B8 CT High leakage current alarm status B9 Program End B10 PV Over range by 5 of span B11 CT Overcurrent alarm status B12 New Alarm Status B13 Timer Ramp Running B14 Remote Fail New Alarm B15 Auto tune Status In each case a setting of ...

Page 155: ...le 1 Using the Wizard Select Promote tab Parameters can be Inserted Edited Removed or Moved up or down the list When inserting or editing a pop up box appears as shown Highlight a parameter and in the Parameter Promotion section select the level of access you wish to be available to the available to the operator and whether it should be Read Write or Read only The list of parameters which are avai...

Page 156: ... Parameters tab 3 Highlight the position where you want the new parameter to be placed 4 Press button and from the pop up window select the required parameter Alternatively use the button 5 In the Level box select Level 2 or Level 1 2 if it is required to display this parameter in Level 1 as well 6 In the Access box select Read Only or Read Write as required 7 Press to remove a selected parameter ...

Page 157: ...Example Using the Browser view 1 Press 2 Select the linearisation table to be loaded from files with the extension mtb Linearisation files for different sensor types are supplied with iTools and may be found in Program Files Eurotherm iTools Linearisations Thermocouple etc 3 In this example a Pt PTRh 10 thermocouple has been loaded into the controller The controller will display the linearisation ...

Page 158: ... 2 Select RECIPE in the browser 3 In RecipeSave select the recipe number e g 1 4 Set the alarm threshold to another value and save in Recipe 2 5 In RecipeNumber choose the recipe to run This can also be done through the controller user interface Any of the 38 parameters can be set up in any of the five recipes using the above procedure It may be more convenient to open more than one parameter list...

Page 159: ... Using the Wizard Select the Recipe tab 17 10 2 1Recipe Definition Select Recipe Definition tab to display the default parameters available to be stored in recipe Double click on the parameter in the Wired From column a pop up allows you to delete or change to a different parameter ...

Page 160: ... ensure the controller accepts the new recipe values select another recipe in the controller itself then go back to the recipe in which the changes were made 17 10 2 3Recipe Names Names can be given to each of the five recipes Each name is limited to a maximum of four characters this being the limit of the characters which can be displayed on the front panel of the controller A character shown as ...

Page 161: ...erminal connections for the functions which have been configured together with a description of each function 17 11 1 Example 1 Using the Wizard Press Summary tab 17 11 2 Example 2 Using the browser view Press A summary of the features configured may be selected using the Summary tab ...

Page 162: ...opy all operational engineering and configuration parameters that are writable The communications address is not copied Every effort has been made to ensure that the information contained within the clone files is a replica of that configured in the instrument It is the users responsibility to ensure that the information cloned from one instrument to another is correct for the process to be contro...

Page 163: ...er Systems Accuracy Test calibration conditions EN14597TR Automatic electronic control Type 1A mandatory automatic reset A with full disconnection number of automatic cycles for each automatic action is 250000 Approval number TR1229 Transmitter PSU Isolation 264Vac double insulated Output Voltage 24Vdc 28mA 33mA Communications serial communications option Protocol Modbus RTU slave Modbus RTU Maste...

Page 164: ...C and OP3 provides full 264V double insulated Functions Control retransmission Note 3 Voltage output can be achieved by external adaptor Remote SP input Calibration Accuracy 0 25 of reading 1LSD Sample Rate 4Hz 250mS Isolation 264Vac double insulated from instrument Resolution 0 5mV for 0 10V input or 2μA for 4 20mA Resolution effective bits 14 bits Drift with temperature 50ppm typical 150ppm wors...

Page 165: ...OP4 Section 9 1 9 A1 ALARM 1 SETPOINT Alarm Parameters Section 12 3 Mnemonic Parameter Description Location A1 BLK ALARM 1 BLOCKING Alarm Parameters Section 12 3 A1 HYS ALARM 1 HYSTERESIS Alarm Parameters Section 12 3 A1 LAT ALARM 1 LATCHING TYPE Alarm Parameters Section 12 3 A1 ST S ALARM 1 OUTPUT Alarm Parameters Section 12 3 A1 TYP ALARM 1 TYPE Alarm Parameters Section 12 3 AD DR COMMUNICATIONS...

Page 166: ...Input List Section 8 1 PV OFS PV OFFSET Input List Section 8 1 R2 G INTEGRAL TIME Control List Section 11 10 Mnemonic Parameter Description Location R A M P U SETPOINT RAMP UNITS Setpoint List Section 10 1 R C F T Filter time constant for the rate of change alarm Modbus addresses section 15 6 R C P V Calculated rate of change of PV in engineering units per minute Modbus addresses section 15 6 REG ...

Page 167: ... 71 DEC P 39 DELAY 90 Derivative Time 61 63 67 DERIVATIVE TIME 25 56 DIGITAL INPUT FUNCTION 44 Dimensions 6 DISPLAY POINTS 39 DISPLAY UNITS 24 39 Display units and resolution 39 Dwell 24 28 31 79 82 83 84 DWELL 1 25 80 E ELAPSED TIME 80 ENT T 79 Event 31 73 76 77 80 82 83 EVENT OUTPUTS 80 F Fault detection 39 FEATURE PASSCODE 36 FILT T 39 FILTER TIME 39 40 62 FORCED MANUAL OUTPUT MODE 57 FORCED OU...

Page 168: ... 16 PROGRAM CYCLE 80 PROGRAM CYCLES 80 Programmer 6 24 29 30 31 79 80 81 82 83 84 Proportional Band 58 61 63 70 88 PROPORTIONAL BAND 25 56 87 Proportional Band Units 70 PROPORTIONAL BAND UNITS 56 PV DERIVATIVE 40 PV INPUT VALUE 39 PV OFFSET 39 Q Quick Start Code 6 13 14 19 21 R r tc 40 ramp 28 29 30 31 53 79 80 81 82 83 84 RAMP RATE 1 25 80 RANGE HIGH LIMIT 39 RANGE LOW LIMIT 39 RC FT 134 RC PV 40...

Page 169: ...MAINING 23 25 80 Timer 27 28 29 79 84 132 TIMER CONFIGURATION 24 79 TIMER END TYPE 24 79 TIMER RESOLUTION 24 79 TIMER START THRESHOLD 24 79 TIMER STATUS 24 79 Tuning 61 63 66 67 Type 1 131 U U CAL 106 UNITS 24 39 52 56 User calibration 39 131 USER CALIBRATION 113 W Wiring 9 16 17 89 91 WKG SP 23 24 www eurotherm co uk 89 114 ...

Page 170: ...User Manual 3200 Series 138 Part No HA028651 Issue 11 0 July 12 21 Certificate of Conformity ...

Page 171: ......

Page 172: ...stems Sp z o o T 48 22 8556010 F 48 22 8556011 E biuro invensys systems pl SPAIN Madrid Eurotherm España SA T 34 91 6616001 F 34 91 6619093 E info eurotherm es invensys com SWEDEN Malmo Eurotherm AB T 46 40 384500 F 46 40 384545 E info eurotherm se invensys com SWITZERLAND Wollerau Eurotherm Produkte Schweiz AG T 41 44 7871040 F 41 44 7871044 E info eurotherm ch invensys com UAE DUBAI Invensys Mid...

Page 173: ...Model 2416 Process Controller User Manual Part No HA025041_12 Date August 2014 ...

Page 174: ...This page is intentionally blank ...

Page 175: ...Alarm annunciation 2 13 2 7 2 Alarm acknowledgement and resetting 2 13 2 7 3 Alarm modes 2 13 2 7 4 Alarm types 2 13 2 7 5 Process alarms 2 13 2 8 Diagnostic alarms 2 14 3 Chapter 3 ACCESS LEVELS 3 1 3 1 THE DIFFERENT ACCESS LEVELS 3 1 3 2 SELECTING AN ACCESS LEVEL 3 2 3 3 Edit level 3 3 3 3 1 Setting operator access to a parameter 3 3 3 3 2 Hiding or revealing a complete list 3 3 3 3 3 Promoting ...

Page 176: ...ation 8 2 8 2 Operation 8 3 8 2 1 To Read Load Current modes 2 and 5 only 8 3 8 2 2 To Display Load Current Continuously in the Lower Readout modes 2 and 5 only 8 3 8 2 3 Display Modes 8 3 8 2 4 How Heater Alarms Are Displayed 8 4 8 3 To Set the Alarm Trip Levels 8 5 8 4 Short Circuit SSR Alarm and Heater Fail Alarm 8 5 8 5 Relay Outputs 8 5 8 6 To Configure PDS Load Current Diagnostics 8 6 8 7 To...

Page 177: ... segment programmer built in as standard The 2416 is available as either a standard controller Model 2416 CC setpoint programming controller Models 2416 CP and 2416 P4 motorised valve controller Model 2416 VC setpoint programming motorised valve controller Models 2416 VP and 2416 V4 This chapter consists of two parts MECHANICAL INSTALLATION ELECTRICAL INSTALLATION Before proceeding please read the...

Page 178: ...n Figure 1 3 2 Insert the controller through the panel cut out 3 Spring the upper and lower panel retaining clips into place Secure the controller in position by holding it level and pushing both retaining clips forward 4 Peel off the plastic film protecting the front of the indicator If the panel retaining clips subsequently need removing in order to extract the controller from the control panel ...

Page 179: ...d upon the type of module installed if any To discover which plug in modules are installed in your controller please refer to the ordering code and wiring data on the labels on the sides of the controller The rear terminal layout is shown below Note The plug in sleeve supplied with high voltage controllers are keyed to prevent a low voltage unit being inserted into them Figure 1 4 Rear terminal la...

Page 180: ...rate in six different ways Heating control Cooling control Alarm output Program event output PDS mode 1 which provides logic heating using a Eurotherm TE10S solid state relay with feedback of a load failure alarm PDSIO mode 2 which provides logic heating using a Eurotherm TE10S solid state relay with feedback of the load current reading and two alarms solid state relay failure and heater circuit f...

Page 181: ... 1 2 and 3 connections To check which modules are installed in your particular controller and which functions they are configured to perform refer to the ordering code and the wiring information on the controller side labels 1 2 5 Communications module The Communications module position will accept any of the modules listed in Table 1 2 below The serial communications can be configured for either ...

Page 182: ... For reasons of safety do not connect to local earth here Local Earth Local Earth Local Earth Local Earth Local Earth HE HF HD Series 2000 Controller Galvanic Isolation Barrier Local Ground Zone 1 Local Ground Zone 1 Local Ground Zone 1 Figure 1 6 EIA 485 wiring 2 wire EIA 485 is a connection which allows up to 32 controllers to be multi dropped from a single communications link over a distance of...

Page 183: ...capability see following chart 1 3 1 Logic Drive Fan Out The logic outputs from the 2400 series controllers are capable of driving more than one solid state relay SSR in series or parallel The following table shows the number of SSRs which can be driven depending on type of SSR S Series P Parallel Drive mA SVDA RVDA TE10S 425S Logic DC Logic DC Logic DC Logic 10V Logic 24V Logic 20mA Logic 18V 20m...

Page 184: ... convention is to configure Output 1 as the RAISE output and Output 2 as the LOWER output The controller does not require a position feedback potentiometer Figure 1 8 Motorised valve controller connections RTD Pt100 Line Neutral Ground PV Motor supply LOWER RAISE Motorised valve T C Comms JA JF BA HA HB HC HD HE HF 1A 1B 2A 2B 3A 3B L N V1 V V mV HA025041 issue 12 Aug 14 1 9 ...

Page 185: ...on 2 Chapter 2 OPERATION This chapter has nine topics FRONT PANEL LAYOUT BASIC OPERATION OPERATING MODES AUTOMATIC MODE MANUAL MODE PARAMETERS AND HOW TO ACCESS THEM NAVIGATION DIAGRAM PARAMETER TABLES ALARM MESSAGES HA025041 issue 12 Aug 14 2 1 ...

Page 186: ...er is in manual mode the MAN light will be lit The Auto Manual button can be disabled in configuration level Run Hold button Press once to start a program RUN light on Press again to hold a program HOLD light on Press again to cancel hold and continue running HOLD light off and RUN light ON Press and hold in for two seconds to reset a program RUN and HOLD lights off The RUN light will flash at the...

Page 187: ... is present the controller reverts to the Home display after 10 seconds 2 2 1 Alarms If the controller detects an alarm condition it flashes an alarm message in the Home display For a list of all the alarm messages their meaning and what to do about them see Alarms at the end of this chapter 2 3 OPERATING MODES The controller has two basic modes of operation Automatic mode in which the output powe...

Page 188: ...its for 0 5 seconds after which you will be returned to the Home display Flashing of the display units may have been disabled in configuration in which case a single press will take you straight to the display shown below Press twice Output power demand The output power demand is displayed in the lower readout This is a read only value You cannot adjust it Press and together to return to the Home ...

Page 189: ...e target output Press once Display Units A single press of will flash the display units for 0 5 seconds after which you will be returned to the Home display Flashing of the display units may have been disabled in configuration in which case you a single press will take you straight to the display shown below Press twice Setpoint To adjust the setpoint value press or Press Pressing from the Output ...

Page 190: ...der can be recognised by the fact that it always shows LiSt in the lower readout The upper readout is the name of the list In the above example AL indicates that it is the Alarm list header List header displays are read only To step through the list headers press Depending upon how your controller has been configured a single press may momentarily flash the display units If this is the case a doub...

Page 191: ...s 2 4 3 Parameter displays Figure 2 4 Typical parameter display Parameter displays show the controller s current settings The layout of parameter displays is always the same the upper readout shows the parameter name and the lower readout its value Alterable parameters can be changed using or In the above example the parameter mnemonic is 1FSL indicating Alarm 1 full scale low and the parameter va...

Page 192: ...20 0 20 0 OP 100 0 m A Auto AmPS 5 rAtE 5 0 run LiSt dur 1 0 StAt run PrG 1 PSP 20 CYC 1 SEG 1 SEG t 1 0 StyP rmP r tGt 200 tYPE End SEG n 3 AL LiSt 2 2 0 1 2 100 3 2 5 HY 2 1 HY 1 1 HY 3 1 Lb t OFF HY 4 1 diAG no 4 2 5 drA OFF tunE OFF drA t 0 8 Adc mAn FF tr 0 FF dv 100 0 rEL 2 1 00 FF Pb 0 0 Lcb2 Auto Hcb2 Auto mtr LiSt tm 30 0 In t OFF bAc t OFF mp t Auto 20 0 o C FASt no tYPE dwEl rES 2 0 0 P...

Page 193: ...Full level See Chapter 3 Access Levels ACCS LiSt Goto OPEr codE PASS Setpoint List Input List Output List Comms List Information List Access List L r Loc SSEL SP 1 SP 1 20 0 rm SP 0 0 SP 2 0 0 rmt t 0 0 rat Off Hb ty Lo Hb 10 OP Hi 100 0 OP Lo 0 0 OPrr OFF CYC H 20 0 ont H Auto Addr 1 LoG H 100 0 LoG L 0 0 LoG A 50 0 LoG t 1000 rES L no LoG v 0 0 mCt 0 hYS H 1 0 FiLt Off SP L 4 0 0 SP H4 100 0 SP2...

Page 194: ...nal in 2416 Set to no SEG d Flash active segment type in the lower readout of the home display no YES This parameter can only be changed when the program is in reset ProG Program edit list Present only in setpoint programming controllers PrG n Select program number Only on 4 program versions Hb Holdback type OFF Lo Hi or bAnd Hb V Holdback value in display units rmP U Ramp units SEc min or Hour fo...

Page 195: ...in minutes diAG Enable Diagnostic alarms no YES Atun Autotune list tunE One shot autotune enable drA Adaptive tune enable drA t Adaptive tune trigger level in display units Range 1 to 9999 Adc Automatic Droop Compensation PD control only Name Description Pid PID list G SP If Gain Scheduling has been enabled see Chapter 4 this parameter sets the PV below which Pid 1 is active and above which Pid 2 ...

Page 196: ...1 H Do not make adjustments using the AdJ parameter unless you wish to change the controller calibration OFS 1 IP calibration offset mV 1 IP measured value at terminals CJC 1 IP Cold Junction Compensation Li 1 IP Linearised Value PV SL PV Select Not operational in 2416 Name Description oP Output list Does not appear if Motorised Valve control configured OP Lo Low power limit OP Hi High power limit...

Page 197: ...age will continue to flash even if the alarm condition no longer exists and will only clear when reset Blocking which means that the alarm will only become active after it has first entered a safe state on power up 2 7 4 Alarm types There are two types of alarm Process alarms and Diagnostic alarms 2 7 5 Process alarms These warn that there is a problem with the process which the controller is tryi...

Page 198: ...ircuit Mode 5 only Ct Sh Current Transformer Short Circuit Indicates that the PDS input is short circuit Mode 5 only Hw Er Hardware error Indication that a module is of the wrong type missing or faulty Check that the correct modules are fitted no io No I O None of the expected I O modules is fitted This error message normally occurs when pre configuring a controller without installing any of the r...

Page 199: ...play shows What you can do Password Protection Operator OPEr In this level operators can view and adjust the value of parameters defined in Edit level see below No Full FuLL In this level all the parameters relevant to a particular configuration are visible All alterable parameters may be adjusted Yes Edit Edit In this level you can determine which parameters an operator is able to view and adjust...

Page 200: ... level Edit Edit level conF Configuration level Access to Read only configuration From the ACCS list display press to codE Then press and together will take you into Read Only Configuration without entering a password This will allow you to view all of the configuration parameters but not adjust them If no button is pressed for ten seconds you will be returned to the Home display Alternatively pre...

Page 201: ...e display list rEAd Makes a parameter or list header read only it can be viewed but not altered HIdE Hides a parameter or list header For example 3 3 2 Hiding or revealing a complete list To hide a complete list of parameters all you have to do is hide the list header If a list header is selected only two selections are available rEAd and HIdE It is not possible to hide the ACCS list which always ...

Page 202: ...ction Proportional band Pb The bandwidth in display units over which the output power is proportioned between minimum and maximum Integral time ti Determines the time taken by the controller to remove steady state error signals Derivative time td Determines how strongly the controller will react to the rate of change of the measured value High Cutback Hcb The number of display units above setpoint...

Page 203: ... is not complete until the measured value has reached the required setpoint 5 After two cycles of oscillation the tuning is completed and the tuner switches itself off 6 The controller then calculates the tuning parameters listed in Table 4 1 and resumes normal control action If you want Proportional only PD or PI control you should set the ti or td parameters to OFF before commencing the tuning c...

Page 204: ...Set the Pb tiand td parameter values according to the calculations given in Table 4 2 Type of control Proportional band Pb Integral time ti Derivative time td Proportional only 2xB OFF OFF P I control 2 2xB 0 8xT OFF P I D control 1 7xB 0 5xT 0 12xT Table 4 2 Tuning values 4 3 1 Setting the cutback values The above procedure sets up the parameters for optimum steady state control If unacceptable l...

Page 205: ... Adc The steady state error from the setpoint which occurs when the integral term is set to OFF is sometimes referred to as droop Adc automatically calculates the manual reset value in order to remove this droop To use this facility you must first allow the temperature to stabilise Then in the autotune parameter list you must set Adc to cALc The controller will then calculate a new value for manua...

Page 206: ...back potentiometer for control purposes The desired control mode is selected in the inst list in configuration level The following parameter list will appear in the navigation diagram shown in Chapter 2 if your controller is configured for motorised valve control Name Description Values mtr Motor list Min Max Default tm Valve travel time in seconds This is the time taken for the valve to travel fr...

Page 207: ...ased The minimum on time determines how accurately the valve can be positioned and therefore the control accuracy The shorter the time the more precise the control However if the time is set too short process noise will cause an excessively busy valve 4 4 3 Inertia and backlash settings The default values are satisfactory for most processes i e OFF Inertia is the time taken for the valve to stop a...

Page 208: ... the parameter Gsch and set it to YES Once gain scheduling has been enabled the parameter G SP will appear at the top of the Pid list in FuLL access level This sets the value at which transfer occurs PID1 will be active when the process value is below this setting and PID2 when the process value is above it The best point of transfer depends on the characteristics of the process Set a value betwee...

Page 209: ...odel 2416 P4 Motorised valve controller with a single program Model 2416 VP four stored programs Model 2416 V4 The 8 segment programmer differs from the other programmers in that it will not provide event outputs Otherwise they all operate in the same way There are seven topics To understand how to select and change parameters in this chapter you will need to have read Chapter 2 Operation and Chap...

Page 210: ...t number of times or repeated continuously If repeated a set number of times then the number of cycles must be specified as part of the program There are five different types of segment Ramp The setpoint ramps linearly from its current value to a new value either at a set rate called ramp rate programming or in a set time called time to target programming You must specify the ramp rate or the ramp...

Page 211: ...when they are overwritten by the stored program values Note When a program is running you cannot alter a cALLed program until it becomes active within that program HOLD light on Holdback Holdback indicates that the measured value is deviating from the setpoint by more than a pre set amount and that the program is in Hold waiting for the process to catch up See Holdback in the section on Automatic ...

Page 212: ...ve To return to the Home display press and together To access the other parameters in the run list continue to press These parameters are shown in the Program run list in Chapter 2 Parameter Tables They show the current status of the active program Temporary changes can be made to the parameters in this run list for example a setpoint ramp rate or an unelapsed time by first placing the programmer ...

Page 213: ...t Holdback is available to freeze the program at its current state should this occur The action of Holdback is the same as a deviation alarm It can be enabled or disabled Holdback has two parameters a value and a type If the error from the setpoint exceeds the set holdback value then the Holdback feature if enabled will automatically freeze the program at its current point and flash the HOLD light...

Page 214: ...ed process value to the setpoint as soon as possible this is the best strategy If rmP b is selected then when power is restored the setpoint starts at servos to the current measured value and then ramps to the target setpoint of the active segment at the last ramp rate used by the program This strategy provides a smoother recovery The two diagrams below illustrate the respective responses Figure 5...

Page 215: ...t header After selecting Configuration mode press until the PROG ConF header is displayed Press Number of programs Use or to select nonE Disable built in 8 segment programmer 1 Enable built in 8 segment programmer For 16 segment programmers nonE no programs 1 One stored program 4 Four stored programs Press Holdback Strategy Use or to select SEG Holdback type to be set in each segment ProG Holdback...

Page 216: ... in 8 segment programmer Use or to select no Event outputs disabled YES Event outputs enabled Note The term Sync appears on 2416 but is not operational and should be set to no It appears in order to maintain software consistency with 2408 and 2404 controllers Press to return to the list header Srvo To PV SYNC no out no 5 8 HA025041 issue 12 Aug 14 ...

Page 217: ...de when the programmer is in the Reset state So before modifying a stored program first make sure that it is in Reset and then follow the procedure below Program edit list From the Home display press until you reach the ProG LiSt header Press Program number This display only appears on the four program controllers Use or to select the number of the program which you wish to modify from 1 to 4 Pres...

Page 218: ...tics of each segment of the program you define the whole program Press Segment type Select the segment type using or rmP rRamp to a new setpoint at a set rate rmP tRamp to a new setpoint in a set time dwEl Dwell for a set time StEP Step to a new setpoint cALL Call another program as a subroutine only available in 4 program controllers EndMake this segment end of program Press The parameters that f...

Page 219: ...ng or Press Ramp Rate Ramp rate for rAtE segments Using or set a value for the ramp rate ranging from 0 00 to 999 9 the units will be the ramp units rmP U set earlier in this sequence Press Duration time Time for a dwEl segment or time to target for a rmP t segment Set the time using or You have set the units earlier in this sequence Press Called program number Only appears for cALL segments 4 pro...

Page 220: ...ce the 2416 has a maximum of three physical outputs although more than one event can be combined onto a single physical output See Chapter 6 Configuration Use or to set OFFOff in the current segment onOn the current segment Press End segment type Use or to select dwEl An indefinite dwell rSEt Reset S OP End Segment Output Power Level Press Power Value End Segment Use or to set the power value in t...

Page 221: ... DIAGRAM CONFIGURATION PARAMETER TABLES X Warning Configuration is protected by a password and should only be carried out by a qualified person authorised to do so Incorrect configuration could result in damage to the process being controlled and or personal injury It is the responsibility of the person commissioning the process to ensure that the configuration is correct Caution It is recommended...

Page 222: ...ns The configuration password is set to 2 when the controller is shipped from the factory Press Once the correct password has been entered there is a two second delay after which the lower readout will change to PASS indicating that access is now unlocked i Note Note A special case exists if the password has been set to 0 In this situation access is permanently unlocked and the lower readout will ...

Page 223: ...change the value of a selected parameter use the and buttons The navigation diagram shows all the lists headers and parameters that can potentially be present in the controller In practice those actually present will vary according to the particular configuration choices you make 6 3 Changing the Passwords There are TWO passwords These are stored in the Password configuration list and can be selec...

Page 224: ... tr OFF m tr OFF nSP 2 SP ConF AL ConF AL1 FSH Ltch no bLoc no AL2 FSL Ltch no bLoc no AL3 OFF Ltch no bLoc no AL4 OFF Ltch no bLoc no PROG ConF PtyP 20 Pwr F cont Srvo to PV out no SYnc no iP ConF inPt k tc CJC Auto inp L 0 0 VaL H 100 0 VaL L 0 0 inp H 50 0 imp Auto HbAc SEG unit o C dEc P nnnn PV ConF rnG H 1200 rnG L 0 FOP no Sbr t Sb OP Pd tr no Fwd t nonE PwrF YES r h diSA m A diSA GSch no b...

Page 225: ...ameters but is dependant upon the exact configuration of the instrument The following sheets show the full list of parameters id rELy Func HEAt VAL L 0 VAL H 100 Out L 4 0 Out H 20 0 in 1 0 0 UAL 1 0 0 in 2 1 0 UAL 2 200 0 in 3 2 0 2A ConF 1A ConF 3A ConF CUSt ConF See parameter tables id reLy Func dIg Sens nor AL1 no AL2 no AL3 no UAL 3 350 0 in 8 7 0 UAL 8 800 0 id reLy Func COOL VAL L 0 VAL H 1...

Page 226: ...Auto Man button EnAb Enabled diSA Disabled r h Front panel Run Hold button EnAb Enabled diSA Disabled PwrF Power feedback on On OFF Off Fwd t Feed forward type none None FEEd Normal feed forward SP FF Setpoint feed forward PV FF PV feed forward Pd tr Manual Auto transfer when no Non bumpless transfer using PD control YES Bumpless transfer Pre loads Manual Reset value Sbr t Sensor break output Sb O...

Page 227: ...rs i Note Pyrometer Emmisivity Controllers which are specifically supplied for pyrometer inputs not Exergen K80 have the curve downloaded in the Custom Input The parameter EmiS Pyrometer Emmisivity appears in the Input List on page 2 15 This parameter is also now correctly adjusted i Note Range If a decimal point was configured negative display and setpoint ranges were limited to 99 9 in previous ...

Page 228: ...inearisation V C 8 point Voltage custom linearisation mA C 8 point milliamp custom linearisation CJC Cold Junction OFF No cold junction compensation Compensation Auto Automatic internal compensation 0o C 0o C external reference 45o C 45o C external reference 50o C 50o C external reference imp Sensor Break Impedance Off Disabled applies to any input Caution If sensor break is disabled the controlle...

Page 229: ...Ltch Latching no YES Evnt mAn bLoc Blocking no YES AL3 Alarm 3 Type see Table A Ltch Latching no YES Evnt mAn bLoc Blocking no YES AL4 Alarm 4 Type see Table A Ltch Latching no YES Evnt mAn bLoc Blocking not if AL4 rAt no YES Table A Alarm types Value Alarm type OFF No alarm FSL PV Full scale low FSH PV Full scale high dEv PV Deviation band dHi PV Deviation high dLo PV Deviation low LCr Load Curre...

Page 230: ...apply if a 16 segment programmer is to be configured PROG Programmer configuration Values Meaning PtyP Programmer type nonE Programmer disabled 1 Single program 4 Four programs HbAc Holdback SEG ProG Holdback is individually selectable in each segment Holdback is applied across the whole Program Pwr F Power fail recovery cont Continue from last setpoint SP rmP b Ramp from PV to SP at last ramp rat...

Page 231: ... Full resolution Int Integer resolution dELy Delay quiet period required by some comms adaptors no No delay YES Delay active 10mS For id pds use this parameter table Func Function nonE No PDSIO function SP oP PDSIO setpoint retransmission PV oP PDSIO PV retransmission Er OP PDSIO error signal retransmission OP oP PDSIO output power retransmission VAL L Retransmitted Value Low VAL H Retransmitted V...

Page 232: ...alve dwn Close motorised valve Only if id LoG SSr 1 PDSIO mode 1 heating Only if id LoG SSr 2 PDSIO mode 2 heating VAL L PID demand signal giving minimum output Out L VAL H PID demand signal giving maximum output Out H Out L Minimum average power Out H Maximum average power SEnS Sense of output Only if Func dIG nor Normal output energises when TRUE e g program events inv Inverted output de energis...

Page 233: ...failure alarm YES no tunE Tuning in progress YES no dc F Voltage output open circuit or mA output open circuit YES no rmt F PDS module connection or remote input open circuit YES no iP1 F Input 1 fail not usable on 2416 YES no nw AL New Alarm has occurred YES no End End of setpoint rate limit or end of program YES no SYnc Program Synchronisation active YES no Not available in 2416 set to no PrG n ...

Page 234: ...lectrical output 2A Module 2 configuration As per module 1 configuration but excluding the SSr 1 SSr 2 options on a logic output 3A Module 3 configuration As per module 2 configuration Cust 8 point Custom Linearisation 1 in 1 Custom input 1 VAL 1 Linearisation Value representing in 1 in 8 Custom input 8 VAL 8 Linearisation Value representing in 8 i Note 1 Custom Linearisation is only available whe...

Page 235: ...Select 0o C CJC calibration point 3 Press to step to GO rtd Select 400Ω as the calibration point HI 0 High impedance 0Volt cal n point HI 1 0 High impedance 1 0 Volt cal n point FACt Restore factory calibration GO Start calibration Select YES with or Wait for calibration to complete no Waiting to calibrate PV point YES Start calibration buSy Busy calibrating donE PV input calibration completed FAI...

Page 236: ...Description Values Meaning PASS Password configuration ACC P Full or Edit level password cnF P Configuration level password Exit Exit configuration no YES i Note When passwords are changed please make a note of the new numbers 6 16 HA025041 issue 12 Aug 14 ...

Page 237: ...alibration User calibration works by introducing a single point or two point offset onto the factory set calibration 7 2 USER CALIBRATION ENABLE The User calibration facility must first be enabled in configuration level by setting the parameter UCAL in the CAL ConF list to YES This will make the User calibration parameters visible in Operator FuLL level This procedure is described in Chapter 6 Con...

Page 238: ...orrect then follow the steps shown below Select FuLL access level as described in Chapter 3 Input list header Press until you reach the input list header Press until you reach the CAL display Calibration type FACt Factory Calibration USEr User Calibration Use or to select FACt Selecting FACt reinstates the factory calibration and allows the application of a single fixed offset Press Set Offset 1 U...

Page 239: ... POINT CALIBRATION The previous section described how to apply an offset or trim calibration which applies a fixed offset over the full display range of the controller A two point calibration is used to calibrate the controller at two points and applies a straight line between them Any readings above or below the two calibration points will be an extension of this straight line For this reason it ...

Page 240: ...ected go to page 7 4 ip1 L Input 1 PV1 calibration low point selected ip1 H Input 1 PV1 calibration high point selected ip2 L Not available in Model 2416 ip2 H Not available in Model 2416 Use to select the parameter for the Low Calibration point of Input 1 ip1 L follow route shown on this page Press Adjust low point calibration This is the display for adjusting the Low Calibration point of Input 1...

Page 241: ...s the display for adjusting the High Calibration point of Input 1 The lower readout is a live reading of the process value which changes as the input changes Feed the desired high point calibration signal to the controller from the calibration source If the lower readout does not show this value then use to adjust the reading to the required value Press to return to the ip List header To protect t...

Page 242: ...iption Meaning pt1 L Low calibration point for Input 1 The factory calibration point at which the low point offset was performed pt1 H High calibration point for Input 1 The factory calibration point at which the high point offset was performed OF1 L Offset Low for Input 1 Calculated offset in display units OF1 H Offset High for Input 1 Calculated offset in display units i Note The value of each o...

Page 243: ...ol It is also designed for single phase operation only There are two modes of operation 1 Mode 1 Detects if there is a break in the heater circuit This includes heater or SSR open circuit A single Load Failure alarm message is displayed on the lower readout of the controller 2 Mode 2 Provides the following Display of true RMS load current On the lower readout of the controller Displays the true RM...

Page 244: ...wired for the mode of operation which is configured Failure to do so may be hazardous in some situations Heater Heater power fuse load dependent L N Controller Fuse 2A T L Alternative current regulator arrangements The Eurotherm TE10 PDS2 contains integral power regulator and intelligent PDCTX The PDCTX can be supplied separately for use with any SSR or logic thyristor unit as shown in the diagram...

Page 245: ...er display Press or until AmPS is displayed in the lower display Current will be displayed in the lower readout continuously when the controller reverts to the HOME display see also Display Modes below 8 2 3 Display Modes SSR RMS On State Current This is the default state when high or low current alarms are configured The load current displayed is the steady state true rms current measured during ...

Page 246: ... HCr Alarm number High Current Used for load overcurrent protection To avoid nuisance tripping due to supply voltage variations set to a value at least 15 above the maximum normal operating current Note This alarm is not intended to provide instantaneous safety protection from short circuit fault conditions The following message is a diagnostic alarm which appears for mode 1 operation only LdF Loa...

Page 247: ...agnostic alarm feature in the Alarm List in the Operator Level Do This This Is The Display You Should See Reason From the HOME display press button until the AL LiSt is displayed This opens the list which contains the diAG mnemonic Press until DiAG is displayed Press or to select YES This activates the diAG mnemonic to allow Diagnostic Alarms to be displayed in the lower readout of the HOME displa...

Page 248: ...o show Func Press or to show SSr1 or SSr 2 as required This shows the function of module The module function is set to PDS mode 1 Press to show VAL L Press or to show 0 0 This is the lower PID demand level To set the minimum PID signal to 0 Press to show VAL H Press or to show 100 0 This is the upper PID demand level To set the maximum PID signal to 100 Press to show OUT L Press or to show 0 0 Thi...

Page 249: ... a relay Alternatively any combination of alarms may be attached to operate a relay using the procedure below Do This This Is The Display You Should See Additional Notes Press PAGE key as many times as necessary to 3A ConF Any output module can be configured for an alarm output provided it is not used for any other purpose eg as a control output In place of 3A you should select the module required...

Page 250: ...ow 8 10 1 To Adjust the Scaling Factor Do This This Is The Display You Should See Additional Notes Press button until inSt Conf is displayed Press until LC Hi is displayed Press or to change the scaling factor Should you wish to read currents lower than 4A using a PDCTX it is necessary to increase the number of turns through the PDCTX and adjust the scaling factor to compensate For example To read...

Page 251: ...optional configuration coding The hardware coding specifies the basic build of the controller and the plug in modules that are fitted Part 1 Hardware coding Part 2 Configuration Basic build Plug in I O modules 2416 Model Module Display number 1 units Function Module Supply 2 Sensor Options voltage Module Range 3 min Comms Range Manual max The controller may have been ordered with just the hardware...

Page 252: ... PID cooling RW Valve lower output PO Program event output 1 Or Alarm 2 select from table A Logic non isolated L2 Fitted unconfigured LC PID cooling Triac T2 Fitted unconfigured TC PID cooling TW Valve lower output DC control non isolated D2 Unconfigured C1 0 20mA cooling C2 4 20mA cooling C3 0 5Vdc cooling C4 1 5Vdc cooling C5 0 10Vdc cooling Comms XX None EIA 485 2 wire Y2 Fitted unconfigured YM...

Page 253: ...o 9999 Y 0 20 mA Linear 0 to 9999 A 4 20 mA Linear 0 to 9999 W 0 5V DC Linear 0 to 9999 G 1 5V DC Linear 0 to 9999 V 0 10V DC Linear 0 to 9999 Custom Sensor inputs replaces type C thermocouple D Type D W3 Re W25 Re 0 to 2399 32 to 4350 E E thermocouple 270 to 1000 450 to 1830 1 Ni Ni18 Mo 0 to 1399 32 to 2550 2 Pt20 Rh Pt40 Rh 0 to 1870 32 to 3398 3 W W26 Re Englehard 0 to 2000 32 to 3632 4 W W26 ...

Page 254: ... to the Technical Construction File The packaging should contain an instrument mounted in its sleeve two mounting brackets for panel installation and an Installation Operating guide Certain ranges are supplied with an input adapter If on receipt the packaging or the instrument are damaged do not install the product but contact your supplier If the instrument is to be stored before use protect from...

Page 255: ...e wiring installations comply with all local wiring regulations For example in the UK use the latest version of the IEE wiring regulations BS7671 In the USA use NEC Class 1 wiring methods The installation must include a power isolating switch or circuit breaker This device should be in close proximity to the controller within easy reach of the operator and marked as the disconnecting device for th...

Page 256: ...it is common practice to replace the temperature sensor while the controller is still powered up Under these conditions as additional protection against electric shock we recommend that the shield of the temperature sensor is grounded Do not rely on grounding through the framework of the machine INSTALLATION REQUIREMENTS FOR EMC To ensure compliance with the European EMC directive certain installa...

Page 257: ...d without error Digital Outputs Relay rating Min 12V 100mAdc Max 2A 264Vac resistive Application heating cooling alarms or program event Single logic output 18Vdc 20mA This output is not isolated from the main process value input Application heating cooling alarms or program event Digital o p functions As per the ordering code Triac rating 1A 30 to 264Vac resistive isolated Analogue outputs Range ...

Page 258: ...om main PV Retransmission of setpoint process value or output General Display Dual 4 digit x 7 segment LED Up to two decimal places Supply 100 to 230Vac 15 48 to 62 Hz 10 W max OR 24Vdc or ac 15 20 10W max Operating ambient 0 to 55 o C and 5 to 90 RH non condensing Storage temperature 10 to 70 o C Panel sealing IP65 Dimensions 48mm wide x 48mm high x 150mm deep Weight 250g EMC standards EN50081 2 ...

Page 259: ...This page is intentionally blank ...

Page 260: ...n aid in operating the equip ment to which the document relates without the prior written permission of Eurotherm Limited Eurotherm Limited pursues a policy of continuous development and product improvement The specifications in this document may therefore be changed without notice The information in this document is given in good faith but is intended for guidance only Eurotherm Limited will acce...

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